106871-2590 ZEXEL 9 400 610 043 BOSCH INJECTION-PUMP ASSEMBLY 9400610043 1068712590

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 610 043 9400610043

ZEXEL 106871-2590 1068712590

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Buy INJECTION-PUMP ASSEMBLY 106871-2590 zexel genuine, new aftermarket engine parts with delivery

Service parts 106871-2590 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106087-5510

3. GOVERNOR 105487-1580

4. SUPPLY PUMP 105207-1140

5. AUTOM. ADVANCE MECHANIS 105636-0770

6. COUPLING PLATE 105663-0260

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-7430

11. Nozzle and Holder ME6H6045A

12. Open Pre:MPa(Kqf/cm2) 17.7{180}/21.6{220}

13. NOZZLE-HOLDER 105031-4500

14. NOZZLE

105015-7310

15. NOZZLE SET

Include in #1:

106871-2590 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 610 043 9400610043

ZEXEL 106871-2590 1068712590

Zexel num

Bosch num

Firm num

Name

106871-2590

9 400 610 043

INJECTION-PUMP ASSEMBLY

Calibration Data:

Adjustment conditions

Test oil
1404 Test oil ISO4113 or {SAEJ967d}

Test oil temperature degC 40 40 45

Nozzle and nozzle holder 105780-8140

Bosch type code EF8511/9A

Nozzle 105780-0000

Bosch type code DN12SD12T

Nozzle holder 105780-2080

Bosch type code EF8511/9

Opening pressure MPa 17.2

Opening pressure kgf/cm2 175

Injection pipe
Outer diameter - inner diameter - length (mm) mm 8-3-600

Overflow valve 132424-0620

Overflow valve opening pressure kPa 157 123 191

Overflow valve opening pressure kgf/cm2 1.6 1.25 1.95

Tester oil delivery pressure kPa 157 157 157

Tester oil delivery pressure kgf/cm2 1.6 1.6 1.6

Direction of rotation (viewed from drive side)
Right R

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 1-2-7-3- 4-5-6-8

Pre-stroke mm 4.8 4.75 4.85

Beginning of injection position
Governor side NO.1

Difference between angles 1
Cyl.1-2 deg. 45 44.5 45.5

Difference between angles 2
Cal 1-7 deg. 90 89.5 90.5

Difference between angles 3
Cal 1-3 deg. 135 134.5 135.5

Difference between angles 4
Cal 1-4 deg. 180 179.5 180.5

Difference between angles 5
Cal 1-5 deg. 225 224.5 225.5

Difference between angles 6
Cal 1-6 deg. 270 269.5 270.5

Difference between angles 7
Cal 1-8 deg. 315 314.5 315.5

Injection quantity adjustment

Adjusting point -

Rack position 8.8

Pump speed r/min 700 700 700

Each cylinder's injection qty mm3/st. 97 94.1 99.9

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point C

Rack position 6.1+-0.5

Pump speed r/min 225 225 225

Each cylinder's injection qty mm3/st. 20 17 23

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(8.8)

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 97 96 98

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1(8.8)

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 105.7 101.5 109.9

Difference in delivery mm3/st. 8.4 8.4 8.4

Fixing the lever *

Injection quantity adjustment_05

Adjusting point E

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 130 110 150

Fixing the lever *

Remarks
After startup boost setting

Timer adjustment

Pump speed r/min 950--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 900

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1000

Advance angle deg. 1.8 1.1 2.5

Timer adjustment_04

Pump speed r/min 1100

Advance angle deg. 3.5 3.5

Timer adjustment_05

Pump speed r/min 1150

Advance angle deg. 6.5 6 7

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Beginning of damper spring operation: DL (2)Excess fuel setting for starting: SXL
----------
DL=4.3-0.2mm SXL=9.4+-0.1mm
----------

Speed control lever angle

F:Full speed
----------

----------
a=21.5deg+-5deg

0000000901

F:Full load I:Idle (1)Stopper bolt setting
----------

----------
a=10deg+-5deg b=23.5deg+-3deg

Stop lever angle

N:Engine manufacturer's normal use S:Stop the pump. (1)Rack position = aa (2)Stopper bolt setting (3)Rack position bb (4)Free (at shipping)
----------
aa=4-0.5mm bb=11.7mm
----------
a=43deg+7deg-5deg b=21.5deg+-5deg c=(10.5deg)

0000001501 MICRO SWITCH

Adjustment of the micro-switch Adjust the bolt to obtain the following lever position when the micro-switch is ON. (1)Speed N1 (2)Rack position Ra
----------
N1=325+-5r/min Ra=5.6mm
----------

Timing setting

(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(40deg)

Information:

Illustration 9 g00293067
(5) Air shutoff solenoid that is mounted in the air intake pipe.
Illustration 10 g00281839
Air Shutoff (Typical Example)
Table 2
(1) Air transfer pipe. (5) Air shutoff solenoid.
(2) Valve assembly. (6) O-ring seal.
(3) Shutoff shaft. (7) Diode assembly.
(4) Governor control shaft. The air shutoff solenoid (5) is located in the air inlet system on the top of the engine. When the air shutoff solenoid (ASOS) is activated, the inlet air to the engine is mechanically shut off. The ASOS can be only activated in two ways:
The ASOS is activated by the overspeed switch (OS).
The ASOS is activated by the emergency stop switch (ES).Fuel Shutoff Solenoid (FSOS)
Illustration 11 g00281970
Fuel Solenoid (Typical Example) (1) Diode assembly. (2) Spring. (3) Governor drive. (4) Fuel solenoid. (5) Shaft.
Illustration 12 g00293070
(4) Fuel shutoff solenoid (FSOS) that is mounted on the governor.The fuel shutoff solenoid (FSOS) (4) is located on the governor or on the fuel injection pump of the engine.When the FSOS is energized, the spring (2) and the shaft (5) will cause the fuel rack to move directly or the fuel rack will move through governor drive (3) to the FUEL OFF position. The FSOS remains energized until the time delay relay causes the circuit of the FSOS to de-energize.Time Delay Relay (TD)
Illustration 13 g00281989
4W-8471 Time Delay Relay The time delay relay is an ON/OFF switch which has two controls. When the electric protection system is energized, one control will immediately activate the time delay relay. The other control will activate a relay after a delay of 9 seconds when a continuous signal is received. The time delay relay has a 70 second OFF delay after the signal is removed from both the input terminal (TD-1) and the input terminal (TD-2).The time delay relay is mounted in the junction box.2301AElectric Governor Control
Illustration 14 g00293071
(1) 2301A Electric Governor Speed Control
Illustration 15 g00293069
Electric governor actuator (EGA) (2) and fuel shutoff solenoid (FSOS) (3). These components are mounted on the top of the engine.The 2301A Electric Governor Control system consists of the following components:
2301A Control
Actuator (EGA)
Magnetic pickup (MPU)The 2301A Electric Governor Control system provides precision engine speed control. The 2301A Control constantly monitors the engine rpm. The control makes necessary corrections to the engine fuel setting through an actuator connected to the fuel system.The engine rpm is measured by the magnetic pickup (MU). The magnetic pickup makes an AC voltage that is sent to the 2301A Control. The 2301A Control then sends a DC voltage signal to the actuator in order to adjust the fuel flow.The actuator changes the electrical signal from the 2301A Control to a mechanical output. The mechanical output of the actuator causes the linkage from the actuator to move the fuel rack. This will increase the flow of fuel to the engine or this will decrease the flow of fuel to the engine. For example, if the engine speed is more than the speed setting, the 2301A Control will decrease the voltage output which